Polycrystalline diamond carbide composites

ABSTRACT

Polycrystalline diamond (PCD) carbide composites of this invention have a microstructure comprising a plurality of granules formed from PCD, polycrystalline cubic boron nitride, or mixture thereof, that are distributed within a substantially continuous second matrix region that substantially surrounds the granules and that is formed from a cermet material. In an example embodiment, the granules are polycrystalline diamond and the cermet material is cemented tungsten carbide. PCD carbide composites of this invention display improved properties of fracture toughness and chipping resistance, without substantially compromising wear resistance, when compared to conventional pure PCD materials.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 09/521,717, filed on Mar. 9, 2000 now U.S. Pat. No. 6. 454,027.

FIELD OF THE INVENTION

This invention relates to polycrystalline diamond materials and methodsof making the same and, more particularly this invention relates topolycrystalline diamond carbide composites having improved properties oftoughness without sacrificing wear resistance when compared toconventional polycrystalline diamond materials.

BACKGROUND OF THE INVENTION

Polycrystalline diamond (PCD) materials known in the art are formed fromdiamond grains or crystals and a ductile metal binder and aresynthesized by high temperature/high pressure processes. Such materialis well known for its mechanical properties of wear resistance, makingit a popular material choice for use in such industrial applications ascutting tools for machining, and subterranean mining and drilling wheresuch mechanical properties are highly desired. For example, conventionalPCD can be provided in the form of surface coatings on, e.g., insertsused with cutting and drilling tools, to impart improved wear resistancethereto.

Traditionally, PCD inserts used in such applications are formed bycoating a carbide substrate with one layer of PCD and one or twotransition layers. Such inserts comprise a substrate, a surface layer,and often a transition layer to improve the bonding between the exposedlayer and the support layer. The substrate is, most preferably, acarbide substrate, e.g., cemented carbide, tungsten carbide (WC)cemented with cobalt (WC—Co).

The coated layer or layers of PCD conventionally may comprise a metalbinder up to about 30 percent by weight to facilitate diamondintercrystalline bonding and bonding of the layers to each other and tothe underlying substrate. Metals employed as the binder are oftenselected from cobalt, iron, or nickel and/or mixtures or alloys thereofand can include metals such as manganese, tantalum, chromium and/ormixtures or alloys thereof. However, while higher metal binder contenttypically increases the toughness of the resulting PCD material, highermetal content also decreases the PCD material hardness, thus limitingthe flexibility of being able to provide PCD coatings having desiredlevels of both hardness and toughness. Additionally, when variables areselected to increase the hardness of the PCD material, typicallybrittleness also increases, thereby reducing the toughness of the PCDmaterial.

Generally, such conventional PCD materials exhibit extremely highhardness, high modulus, and high compressive strength, and provide ahigh degree of wear protection to a cutting or drilling element.However, in more complex wear environments known to cause impact andfretting fatigue, layers formed from conventional PCD can fail by grosschipping and spalling. For example, drilling inserts coated with a thickPCD monolayer may exhibit brittleness that causes substantial problemsin practical applications. Conventional methods of improving theperformance of PCD layers include optimizing grain size and controllingcobalt content to increase toughness, but the effect of these methods islimited.

Cemented tungsten carbide (WC—Co), on the other hand, is a cermetmaterial that is well known for its mechanical properties of hardness,toughness and wear resistance, making it a popular material of choicefor use in such industrial applications as subterranean mining anddrilling. Cermet materials refer to materials that contain both aceramic and a metallic element. Popular cermet materials includes thosecomprising hard grains formed from a carbide, boride, nitride, orcarbonitride compound that includes a refractory metal such as W, Ti,Mo, Nb, V, Hf, Ta, Cr, and that comprises a further metallic cementingor binding agent. Cemented tungsten carbide is a well known cermet.Because of the above-described desired properties, cemented tungstencarbide has been the dominant material used, inter alia, in cutting toolapplications for machining, and in subterranean drilling applicationssuch as hard facing, wear inserts, and cutting inserts in rotary conerock bits, and substrate bodies for drag bit shear cutters.

The mechanical properties associated with cemented tungsten carbide andother cermets, especially the unique combination of hardness toughnessand wear resistance, make these materials more desirable than eithermetals or ceramics alone. Compared to PCD, WC—Co is known to display asignificantly higher fracture toughness and chipping resistance.However, WC—Co has less wear resistance and hardness than PCD.

U.S. Pat. No. 4,525,178 discloses a composite material comprising a PCDbody having cemented carbide pieces disposed therein formed by combiningindividual diamond crystals with pieces of precemented carbide. Theso-formed PCD composite provides improved properties of impactresistance when compared to pure PCD materials, i.e., PCD materials thatdo not include cemented carbide. However, cutting substrates and/orworking surfaces formed from such PCD composite are still known to chipand suffer other types of impact related material failures when exposedto aggressive cutting and/or drilling applications.

U.S. Pat. No. 5,370,195 discloses drill bit inserts comprising a PCDouter layer, an outer transition layer disposed onto an insertsubstrate, and an inner transition layer interposed between the outertransition layer and the PCD outer layer. The PCD outer layer comprisesa minor volume percent of metal and a trace amount of WC or otherceramic additives. The inner and outer transition layers are essentiallydiamond-carbide composites. Each comprises diamond crystals (i.e., notPCD), particles of tungsten carbide, cobalt, and titanium carbonitridein different volume percentages. Although this diamond-carbide compositedoes provide some degree of improved impact resistance when compared toa pure PCD material, cutting substrates and/or working surfaces formedfrom this diamond-carbide composite are known to have greatly reducedwear resistance as compared to PCD. The transition layers are stilllikely to chip and suffer other types of impact related failures whenexposed to aggressive cutting and/or drilling applications.

It is, therefore, desirable that a composite material be constructedthat provides desired PCD properties of hardness and wear resistancewith improved properties of fracture toughness and chipping resistance,as compared to conventional PCD materials, for use in aggressive cuttingand/or drilling applications. It is desired that such composite materialdisplay such improved properties without adversely impacting theinherent PCD property of wear resistance. It is desired that suchcomposite material be adapted for use in such applications as cuttingtools, roller cone bits, percussion or hammer bits, drag bits and othermining, construction and machine applications, where properties ofimproved fracture toughness is desired.

SUMMARY OF THE INVENTION

PCD carbide composites of this invention are specifically designed toprovide an improved degree of fracture toughness and chippingresistance, without substantially sacrificing wear resistance, whencompared to conventional pure PCD materials. Generally speaking, PCDcarbide composites of this invention have a microstructure comprising afirst region made up of a plurality of granules formed from materialsselected from the group consisting of polycrystalline diamond,polycrystalline cubic boron nitride, and mixtures thereof. The firstregion granules are distributed within a substantially continuous secondregion matrix that substantially separates the first region granulesfrom one another. The second region is a cermet material, e.g., formedfrom the group materials including carbides, nitrides, carbonitrides,borides, and mixtures thereof.

In an example embodiment, the first region granules are PCD having anaverage granule size in the range of from about 50 to 1,000 micrometers,and preferably within the range of from about 100 to 500 micrometers. Inthe same example embodiment, the second region cermet has a carbide hardgrain phase and a ductile metal binder phase, wherein the carbide hardgrain phase is selected from the group of carbides comprising W, Ti, Mo,Nb, V, Hf, Ta, and mixtures thereof. The second region ductile metalbinder phase is selected from the group consisting of Co, Ni, Fe, alloysthereof, and alloys with materials selected from the group consisting ofC, B, Cr, Si, and Mn. In an preferred example embodiment, the secondregion cermet is cemented tungsten carbide (WC—Co).

PCD carbide composites of this invention comprise in the range of from10 to 90 percent by volume first region materials, and preferablycomprise in the range of from about 30 to 80 percent by volume firstregion materials, based on the total volume of the composite.

PCD carbide composites of this invention are prepared by combiningpowder selected from the group consisting of carbides, nitrides,carbonitrides, borides, and mixtures thereof, with a ductile metalpowder, and powder selected from the group consisting of diamond, cubicboron nitride, and mixtures thereof, to form a mixture. The mixture ofpowders is then pressurized under elevated temperature conditions toform the PCD composite.

PCD carbide composites of this invention, having improved properties offracture toughness and chipping resistance, are more durable and providea longer service life than conventional PCD materials when used inapplications that are subjected to extreme abrasion and impactconditions. For example, PCD carbide composites of this invention arewell suited for use in such applications as roller cone drill bits,percussion or hammer bits, drag bits, and other applications such asmining and construction tools where the combined properties of wearresistance, hardness, fracture toughness, and chipping resistance isdesired.

DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention willbecome appreciated as the same becomes better understood with referenceto the specification, claims and drawings wherein:

FIG. 1 is a schematic photomicrograph of a portion of a conventionalpolycrystalline diamond material;

FIG. 2 is a schematic photomicrograph of a portion of a polycrystallinediamond carbide composite prepared according to principles of thisinvention;

FIG. 3 is a schematic perspective side view of an insert comprising apolycrystalline diamond composite of this invention;

FIG. 4 is a perspective side view of a roller cone drill bit comprisinga number of the inserts of FIG. 3;

FIG. 5 is a perspective side view of a percussion or hammer bitcomprising a number of inserts comprising a polycrystalline diamondcarbide composite of this invention;

FIG. 6 is a schematic perspective side view of a shear cutter comprisinga polycrystalline diamond carbide composite of this invention;

FIG. 7 is a perspective side view of a drag bit comprising a number ofthe shear cutters of FIG. 6; and

FIG. 8 is a schematic photomicrograph of a polycrystalline diamondgranule prepared from a granulated coated diamond particle.

DETAILED DESCRIPTION

As used in this specification, the term polycrystalline diamond, alongwith its abbreviation “PCD,” refers to the material produced bysubjecting individual diamond crystals or grains and additives tosufficiently high pressure and high temperature that intercrystallinebonding occurs between adjacent diamond crystals. A characteristic ofPCD is that the diamond crystals be bonded to each other to form a rigidbody. Metallic additives such as cobalt are used to fill the voids inbetween the diamond crystals. Higher metal content usually improvesimpact resistance. PCD may also contain other additives such as WC orother carbides or nitrides. Polycrystalline diamond (PCD) carbinecomposites of this invention generally comprise a first hard region inthe form of PCD granules, surrounded by a continuous second regionmatrix formed from a relatively softer and more ductile cermet materialsuch as cemented tugsten carbide (WC—Co). PCD carbide composites of thisinvention provide improved properties of fracture toughness and chippingresistance when compared to conventional PCD materials, withoutsacrificing the inherent PCD properties of wear resistance.

FIG. 1 is a microstructure of a conventional PCD material 10 comprisingdiamond grains 12 that are bonded to one another by a binder material14, e.g., cobalt. Desired properties of such conventional PCD materialsare, for example, wear resistance, high modulus, and high compressivestrength. Such conventional PCD materials may comprise a binder materialor metal content up to about 30 percent by weight, and the metalsemployed as the binder can include Co, Ni, Fe, and mixtures thereof. Theparticular amount of the metal component that is used is typicallycontrolled to provide a compromise between such properties as toughnessand hardness.

For conventional PCD materials, the properties of toughness and hardnessare inversely related to one another and are dependent on the relativeamount of metal and diamond grains used to form the material. Thepresence of diamond grains and related diamond bonding is necessary toprovide properties of high strength and wear resistance to the material.However, too much diamond grains or diamond bonding in the material willproduce an undesired level of chipping resistance. The presence of metalin the PCD material can help to improve chipping resistance butadversely impact the PCD material properties of high strength and wearresistance. Therefore, the amount of metal that is used to form the PCDmaterial is preferably that amount that provides a desired improvementin chipping resistance without significantly impacting strength and wearresistance. The compromise in these mechanical properties makesconventional PCD unsuited for use in certain demanding applications thatcall for a high degree of chipping resistance, strength, and wearresistance.

Referring still to FIG. 1, it is evident that the binder material 14 isnot continuous throughout the microstructure in the conventional PCDmaterial. Rather, the microstructure of the conventional PCD materialhas a uniform distribution of cobalt binder among the PCD granules.Thus, crack propagation through the conventional PCD material will oftentravel through the less ductile and brittle diamond grains, eithertransgranularly through diamond grain/cobalt interfaces 15, orintergranularly through the diamond grain/diamond grain interfaces 16.As a result, conventional PCD materials often exhibit gross brittlefracture during more demanding applications, which may lead tocatastrophic material and part failure.

FIG. 2 illustrates a microstructure of a PCD carbide composite 18,prepared according to principles of this invention, having amicrostructure comprising a first hard region 20 dispersed within asecond relatively softer and substantially continuous matrix region 22.The first region 20 is formed from granules of a hard material selectedfrom the group consisting of PCD, polycrystalline cubic boron nitride(PCBN), and mixtures thereof. In an example embodiment, the first region20 comprises PCD granules. As discussed in greater detail below, the PCDgranules can either be provided in pre-sintered form as diamond granulesprepared from synthetic diamond powder having a desired content ofbinder metal, e.g., cobalt, or as granulated diamond particles preparedby granulating a diamond powder, binder metal and organic binding agentprecursor, and then coating the granulated diamond precursor with adesired metal or cermet. Alternatively, the granulated diamond precursorcan be used without further coating.

In an example embodiment, where the PCD granules are formed fromsynthetic diamond powder and binder metal, the first region comprisesPCD granules having diamond grains that range from submicrometer in sizeto 50 micrometers, and a binder metal, e.g., cobalt, present in therange of from about 10 to 20 percent by weight of the total PCD granule.In another example embodiment, where the PCD granules are formed fromcoated granulated diamond precursor, the first region comprises PCDgranules having diamond grains sized in the range of from 1 to 50micrometers, and a binder metal, e.g., cobalt, present up to about 30percent by weight of the total PCD granule.

In a first example, the PCD granules can be prepared by blendingsynthetic diamond powder with a polymer binder, and pelletizing thediamond and polymer mix into small diamond pellets or granules. Ifdesired, the so-formed diamond granules can be further coated with ametal or cermet material. The so-formed diamond granules can haveequi-axe shapes, e.g., are in the form of polygons or spheres, or can bein the form of short fibers. It is to be understood that the diamondgranules useful for forming PCD composites of this invention can have avariety of different shapes and configurations, e.g., elongated plates,discs, short fibers, or the like, which may or may not be useful forproviding a desired performance characteristic. For example, diamondgranules of this invention can be configured to provide particular crackpropagation characteristics within the composite. Each of the diamondgranules comprise a plurality of diamond grains and a minor amount ofbinder metal such as cobalt.

The polymer binders useful for forming diamond granules can includethermoplastic materials, thermoset materials, aqueous and gelationpolymers, as well as inorganic binders. Suitable thermoplastic polymersinclude polyolefins such as polyethylene, polyethylene-butyl acetate(PEBA), ethylene vinyl acetate (EVA), ethylene ethyl acetate (EEA),polyethylene glycol (PEG), polysaccharides, polypropylene (PP), polyvinyl alcohol (PVA), polystyrene (PS), polymethyl methacrylate, polyethylene carbonate (PEC), polyalkylene carbonate (PAC), polycarbonate,poly propylene carbonate (PPC), nylons, polyvinyl chlorides,polybutenes, polyesters, waxes, fatty acids (stearic acid), natural andsynthetic oils (heavy mineral oil), and mixtures thereof.

Suitable thermoset plastics useful as the presintered PCD granulepolymer binder include polystyrenes, nylons, phenolics, polyolefins,polyesters, polyurethanes. Suitable aqueous and gelation systems includethose formed from cellulose, alginates, polyvinyl alcohol, polyethyleneglycol, polysaccharides, water, and mixtures thereof. Silicone is anexample inorganic polymer binder.

An exemplary diamond granule polymer binder is ethylene vinyl acetateand heavy mineral oil, which is preferred because of its ability to beextruded and pultruded in fine fibers. In addition, the backbone (EVA)is insoluble in heptane and alcohol.

In a second example, the PCD granules are prepared by taking a diamondprecursor material (formed from diamond powder, an organic binder, andbinder metal), granulating the diamond precursor material, and coatingthe granulated diamond with a desired metal. Suitable diamond precursormaterials include diamond tape that is formed by combining syntheticdiamond powder with a binder material, e.g., cobalt, and an organicbinder, and forming the combined mixture into a desired sheet or web.Diamond powder and binder metal powder can be the same as that describedabove for forming PCD granules according to the first example. Suitableorganic binders include the same types of polymer binders describedabove.

The diamond precursor is granulated into desired size particles, e.g., adiamond precursor in the form of diamond tape is chopped into smallparticles, wherein each particle comprises a combination of diamondpowder, metal binder powder, and organic binder. The so-formedgranulated diamond particles are then coated with a desired cermet ormetal material by conventional process such as by ball milling and thelike. The granulated diamond particles can be coated with a ductilemetal binder material such as that selected from the group including Co,Fe, Ni, and combinations thereof, or can be coated with a cermetmaterial that includes hard grains of carbides, nitrides, carbonitridesor borides or a mixture thereof formed from refractory metals such as W,Ti, Mo, Nb, V, Hf, Ta, Cr, and that may further include a metalliccementing agent. Alternatively, the granulated diamond particles can beused to form PCD granules of this invention without further coating isso desired.

PCD granules prepared from granulated diamond particles have amicrostructure that is different from that of PCD granules prepared fromsynthetic diamond powder.

FIG. 8 illustrates a PCD granule 54 prepared from a granulated andcoated diamond particle that comprises a diamond cell 56 that itselfcomprises a plurality of diamond grains 58 and binder metal 60interposed between the diamond grains. The diamond cell 56 issubstantially surrounded, i.e., in three dimensions, by a metal orcermet material 62. In an example embodiment, so-formed PCD granuleseach comprise a plurality of such diamond cells that are separated fromone another by a cell boundary formed from the metal or cermet material.In a preferred example, each cell boundary is formed from WC—Co. On theother hand, PCD granules prepared from synthetic diamond powder have amicrostructure lacking the diamond cells and cell boundaries, onlycomprising diamond grains and binder metal interposed therebetween (seeFIG. 1).

A PCD granule microstructure comprising diamond cells that aresubstantially surrounded by a WC—Co cell boundary, for example, canprovide improved properties of fracture toughness to PCD carbidecomposites of this invention because the cell boundary can function todeflect crack propagation away from the diamond cell.

PCD carbide composites of this invention include PCD granules having anaverage post-sintered granule diameter in the range of from about 50 to1,000 micrometers. The size of the

As used in this specification, the term polycrystalline diamond, alongwith its abbreviation “PCD,” refers to the material produced bysubjecting individual diamond crystals or grains and additives tosufficiently high pressure and high temperature that intercrystallinebonding occurs between adjacent diamond crystals. A characteristic ofPCD is that the diamond crystals be bonded to each other to form a rigidbody. Metallic additives such as cobalt are used to fill the voids inbetween the diamond crystals. Higher metal content usually improvesimpact resistance. PCD may also contain other additives such as WC orother carbides or nitrides. Polycrystalline diamond (PCD) carbinecomposites of this invention generally comprise a first hard region inthe form of PCD granules, surrounded by a continuous second regionmatrix formed from a relatively softer and more ductile cermet materialsuch as cemented tugsten carbide (WC-Co). PCD carbide composites of thisinvention provide improved properties of fracture toughness and chippingresistance when compared to conventional PCD materials, withoutsacrificing the inherent PCD properties of wear resistance. PCD granuleswill depend on the particular PCD carbide composite application that isanticipated, as the PCD granule size can influence such compositemechanical properties as fracture toughness, chipping resistance, andwear resistance. Generally, the use of larger PCD granules can produce acomposite having good wear resistance but poor chipping resistance,while the use of smaller PCD granules may provide a composite havingreduced fracture toughness.

A preferred PCD granule size is in the range of from about 100 to 500micrometers. Within this preferred size range, PCD granules possess allbulk mechanical properties of polycrystalline diamond materials such asextremely high wear resistance and high strength. However, PCD materialsare still prone to chipping due to the inherent PCD property ofbrittleness. PCD granules sized greater than about 500 micrometers canproduce a composite that is more likely to cause macro chipping andspalling of the entire composite in response to surface chips, PCDgranules sized less than about 100 micrometers may not have the massproperties and robustness that is needed to provide a desired degree ofwear resistance in extremely abrasive and highly-loaded environments.The smaller particles are also prone to be up-rooted or displaced whenpreferential wear occurs to the surrounding matrix.

The second region 22 is formed from a cermet material that includes hardgrains of carbides, nitrides, carbonitrides or borides or a mixturethereof formed from refractory metals such as W, Ti, Mo, Nb, V, Hf, Ta,Cr, and that further includes a metallic cementing agent. Example hardgrain materials include WC, TiC, TiN, TiCN, TaC, TiB₂, or Cr₂C₃. Themetallic cementing agent may be selected from the group of ductilematerials including one or a combination of Co, Ni, Fe, which may bealloyed with each other or with C, B, Cr, Si and Mn. Preferred cermetsuseful for forming the second region 22 include cemented tungstencarbide with cobalt as the binder phase (WC—Co), and other cermets suchas WC—Ni, WC—Fe, WC—(Co, Ni, Fe) and alloys thereof.

Cemented tungsten carbide, useful for forming the second region 22 ofPCD carbide composites of this invention, can comprise in the range offrom about 75 to 97 percent by weight carbide component, and metalliccementing agent or binder in the range of from about 3 to 25 percent byweight based on the total weight of the cermet. As described below, thecarbide component and binder component used to form the second regioncermet material are provided in powder form and mixed with thepresintered PCD granules, and then subjected to high-temperature,high-pressure processing to form the PCD composite. If desired, thesecond region 22 can comprise a percentage of spherical cast carbide,e.g., spherical cast carbide fabricated using the spinning disk rapidsolidification process described in U.S. Pat. No. 4,723,996 and U.S.Pat. No. 5,089,182.

The respective amount, e.g., volume fraction, of the first and secondregions 20 and 22 making up PCD carbide composites of this inventiondetermine the combined mechanical and tribological behavior of the finalcomposites so formed. PCD carbide composites of this invention maycomprise in the range of from about 10 to 90 percent by volume of thefirst region granules 20, and preferably from about 30 to 80 percent byvolume of the first region, based on the total volume of the composite.The volume fraction of the first region granules is one of the mostimportant factors affecting the mechanical properties of the finalcomposite.

Using less than about 30 percent by volume of the first region granulesis not desired as such is an ineffective amount of PCD necessary toprovide a desired level of wear resistance for demanding applicationssuch as shear cutter substrates for drag bits or inserts for roller conerock bits. Using greater than about 80 percent by volume of the firstregion granules may not be desired for certain demanding applicationsbecause it: (1) increases the contiguity between PCD granules to a levelcausing macro chipping and reducing impact and spalling resistance(wherein contiguity measures the degree of granule to granule contact,and the greater the degree of contiguity the higher the number ofcontacts between PCD granules); and (2) reduces the amount of the secondregion material present in the composite to an ineffective amountnecessary to provide desired mechanical properties of fracture toughnessand chipping resistance for the same types of demanding applications.

The exact amount of the first region granules 20 that are used to formPCD carbide composites of this invention will vary depending on thedesired mechanical properties for a particular application. For example,when the composite comprises PCD as the first region material and WC—Coas the second region material, and is used as a wear or cutting surfaceon an earth boring drill bit, it is preferred that the first regionmaterial be present in the range of from about 40 to 60 percent byvolume of the total volume of the composite.

Broadly speaking, PCD carbide composites of this invention are made bymingling PCD or PCBN hard granules with a relatively softer and toughercermet matrix under conditions that cause the hard granules to form astrong bond with the cermet matrix. PCD carbide composites of thisinvention have a microstructure that provides a much higher fracturetoughness and chipping resistance than conventional 100 percent PCDmaterials due to the enhanced crack blunting and deflective effects ofthe continuous cermet second region 22 that surrounds each first regiongranule 20. The continuous second region increases the overall fracturetoughness of the composite, by blunting or deflecting the front of apropagating crack if one occurs, without sacrificing the wear resistanceof the composite.

PCD carbide composites of this invention are initially formed from greenparts that can be sintered by high-temperature high-pressure process,which results in the desired composite microstructure of a uniformdistribution of PCD granules within the relatively softer and toughercermet matrix, thereby producing improved properties of fracturetoughness without sacrificing wear resistance.

Initially, the hard region PCD or PCBN granules are formed by the methoddescribed above comprising combining synthetic diamond powder with asuitable polymer binder, and pelletizing the mixture to form the green,i.e., presintered, diamond granules.

The second region cermet, e.g., WC—Co, is formed by either combining WCpowder with Co powder and a polymer binder, or by combining WC—Co powderwith a polymer binder, to form a slurry. A solvent can optionally beused to prepare the slurry to help control the its viscosity forprocessing. Suitable WC, WC—Co, and/or Co powders useful for forming thesecond region includes those having an average particle size of lessthan about 100 micrometers, and preferably less than about 30micrometers. It is desired that the amount of Co used to form the secondregion be in the range of from about 3 to 30 percent by weight based onthe total weight of the WC and Co components.

The polymer binder used to form the slurry can be the same as ordifferent from that used to form the diamond granules. It may be desiredto use different polymer binders so that the diamond granules remainintact when they are combined with the slurry. Suitable solvents includeheptane, methyl-ethyl ketone, methyl chloride, toluene, water, alcohol,acetone, mineral spirits, and mixtures thereof. In a preferredembodiment, the polymer binder is polyethylene-butyl acetate, whichexhibits excellent formability at temperature and is soluble in heptaneand alcohol.

The slurry comprises in the range of from about 40 to 90 percent byweight powder, in the range of from about 1 to 20 percent by weightpolymer binder, and up to about 60 percent by weight solvent based onthe total weight of the slurry. The provided ranges for theseingredients are important to both aid in processing the slurry beforesintering, and to prevent unwanted cracking during heating.

The diamond granules are thoroughly mixed with the WC and Co powderslurry, and any solvent is extracted and collected for recycling.Alternatively, at this stage sintered PCD granules can be used if itcost effective. The diamond granules (or sintered PCD granules), WC, andCo mixture are then formed by shaping into sheets, plates, rods, or anyother desired planar or nonplanar shape as green stock, e.g., in theshape of a cap for a rock bit insert. The green parts are thermallydebinded and then sintered by high-temperature, high-pressure processfor diamond synthesis. The sintered product is the PCD carbide compositeof this invention having a microstructure comprising PCD granulesembedded in one substantially continuous WC—Co matrix.

PCD carbide composite constructions of this invention will become betterunderstood and appreciated with reference to the following examples:

EXAMPLE No. 1 PCD Carbide Composite Comprising PCD Granules Formed fromSynthetic Diamond Powder, Metal Powder, and Polymeric Binder

Diamond granules for forming the first region of the PCD carbidecomposite were made according to the mixing and palletizing stepsdescribed, from grade 817 synthetic diamond powder available fromMegaDiamond of Provo, Utah. The so-formed diamond granules had anaverage presintered granule size of from 300 to 400 micrometers. Thepolymer binder that was used to form the diamond granules were ethylenevinyl acetate. The second region was formed from WC—Co powder taken fromTCM grades 411, 510, 614, or 616, available from Kennametal of Latrobe,Pennsylvania. The polymer binder used to form the WC and Co slurry waspolyethylene-butyl acetate.

The diamond granules and WC and Co slurry were combined and a green partwas formed from the mixture. The green part was thermally debinded atfrom 200 to 400° C. The thermally debinded green part was sintered byhigh-temperature, high-pressure process at approximately 1,400° C. andapproximately 55 megapascals for approximately 120 seconds. The volumefraction of PCD granules in the post-sintered composite was in the rangeof from 70 to 80 percent.

EXAMPLE No. 2 PCD Carbide Composite Comprising PCD Granules Formed fromGranulated and Coated Diamond Particles

Diamond granules for forming the first region of the PCD carbidecomposite were made from diamond tape comprising synthetic diamondpowder and an organic binder. A small amount of binder metal, e.g.,cobalt, was either present in the synthetic diamond powder or was addedas a separate metal powder. The diamond tape was chopped or granulatedinto a desired size, e.g., cubes, and was introduced into a ball millcontaining WC—Co balls. Alternatively, the granulated diamond tape couldbe milled with a WC medial in a polypropylene bottle. The milledgranulated diamond particles were within the range of from 50 to 1000micrometers in size. The granulated diamond particles and WC Co slurrywere combined and a green part was formed from the mixture. The greenpart was thermally debinded at from 200 to 400° C. The thermallydebinded green part was sintered by high-temperature, high-pressureprocess at approximately 1,400°C. and approximately 55 megapascals forapproximately 120 seconds. The volume fraction of PCD granules in thepost-sintered composite was in the range of from 70 to 80 percent.

PCD carbide composites of this invention display improved physicalproperties of fracture toughness and chipping resistance, withoutsacrificing wear resistance, when compared to conventional pure PCDmaterials, which result is due to the special architecture of themicrostructure, comprising the hard first region granules that act tocontrol the wear rate of the composite, surrounded by the toughercontinuous second region matrix that provides a crack blunting and crackinterruption, i.e., a fracture energy absorbing, effect.

PCD carbide composites of this invention can be used in a number ofdifferent applications, such as tools for machining, cutting, mining andconstruction applications, where mechanical properties of high fracturetoughness and wear resistance are highly desired. PCD carbide compositesof this invention can be used to form wear and cutting components insuch tools as roller cone bits, percussion or hammer bits, drag bits,and a number of different cutting and machine tools. PCD carbidecomposites can be used to form a wear surface in such applications inthe form of one or more substrate coating layers, or can be used to formthe substrate itself. An advantage of PCD carbide composites of thisinvention that are used in the form of a surface coating is that, whendisposed over a cemented tungsten carbide substrate, the composite willdisplay a reduced level of residual stress due to the relativemechanical and thermal matching between the composite and the substratewhen compared to a coating of pure PCD.

FIG. 3, for example, illustrates a mining or drill bit insert 24 that iseither formed from or is coated with a PCD carbide composite. Referringto FIG. 4, such an insert 24 can be used with a roller cone drill bit 26comprising a body 28 having three legs 30, and a cutter cone 32 mountedon a lower end of each leg. Each roller cone bit insert 24 can befabricated according to one of the methods described above. The inserts24 are provided in the surfaces of the cutter cone 32 for bearing on arock formation being drilled.

Referring to FIG. 5, inserts 24 formed from PCD carbide composites ofthis invention can also be used with a percussion or hammer bit 34,comprising a hollow steel body 36 having a threaded pin 38 on an end ofthe body for assembling the bit onto a drill string (not shown) fordrilling oil wells and the like. A plurality of the inserts 24 areprovided in the surface of a head 40 of the body 36 for bearing on thesubterranean formation being drilled.

Referring to FIG. 6, PCD carbide composites of this invention can alsobe used to form PCD shear cutters 42 that are used, for example, with adrag bit for drilling subterranean formations. More specifically, PCDcarbide composites of this invention can be used to form a sinteredsurface layer on a cutting or wear surface of the shear cutter substrate44. Referring to FIG. 7, a drag bit 48 comprises a plurality of such PCDshear cutters 42 that are each attached to blades 50 that extend from ahead 52 of the drag bit for cutting against the subterranean formationbeing drilled.

Although, limited embodiments of PCD carbide composites and applicationsfor the same, have been described and illustrated herein, manymodifications and variations will be apparent to those skilled in theart. For example, while PCD carbide composites of this invention havebeen described as being useful to form a working surface on a particularsubstrate, it is to be understood within the scope of this inventionthat PCD carbide composites of this invention can also be used to formmultiple layer structure, or to form the substrate itself, e.g., a shearcutter.

Accordingly, it is to be understood that within the scope of theappended claims, PCD carbide composites of this invention may beembodied other than as specifically described herein.

1. A method for making a composite material comprising the steps of:combining a powder selected from the group consisting of diamond, cubicboron nitride, and mixtures thereof, with a first polymer binder to forma first mixture, and forming the first mixture into a plurality ofgranules; combining one or more powders selected from the groupconsisting of materials having a degree of ductility that is greaterthan that of the granules with a second polymer binder to fonn a secondmixture in the form of a slurry; combining the plurality of granuleswith the second mixture, and forming the combined granules and secondmixture into a green-state part; and subjecting the green-state part toa high-temperature high-pressure process to provide a sintered compositemicrostructure comprising the plurality of granules distributed within asubstantially continuous matrix formed from the second mixture, whereinsintered composite microstructure comprises in the range of from about30 to 80 percent by volume granules based on the total volume of thecomposite.
 2. The method as recited in claim 1 wherein the continuousmatrix comprises a hard phase material and a ductile phase material,wherein the hard phase material is a carbide selected from the groupconsisting W, Ti, Mo, Nb, V, Hf, Ta, and Cr, and the ductile phasematerial is selected from the group consisting of Co, Ni, Fe, alloysthereof.
 3. The method as recited in claim 1 wherein the granules arepolycrystalline diamond and the continuous matrix is cemented tungstencarbide, and wherein after the sintering step the granules arepolycrystalline diamond.
 4. The method as recited in claim 1 wherein thecomposite material comprises in the range of from 10 to 90 volumepercent of the granules based on the total volume of the compositematerial.
 5. The method as recited in claim 1 wherein the granules havean average granule size in the range of from about 50 to 1,000micrometers.
 6. The method as recited in claim 5 wherein the granuleshave an average granule size in the range of from about 100 to 500micrometers.
 7. The method as recited in claim 1 wherein the first andsecond polymer binders are selected from the group of materialsconsisting of thermoplastics, thermosets, aqueous polymers, gelationpolymers, and mixtures thereof.
 8. The method as recited in claim 7wherein the first and second polymer binders are different.
 9. A methodfor forming a composite material comprising the steps of: combining apowder selected from the group of unsintered precursor materialsconsisting of diamond, cubic boron nitride, and mixtures thereof, with afirst polymer binder to form a first mixture; forming the first mixtureinto a plurality of granules; combining one or more powder selected fromthe group of unsintered precursor materials consisting of cermets,carbides, nitrides, carbonitrides, boricles, cobalt, iron, nickel, andmixtures thereof, with a second polymer binder that is different fromthe first polymer binder to form a second mixture in the form of aslurry; combining the plurality of granules with the second mixture toform a third mixture and forming the third mixture into a green-statepart; and subjecting the green-state part to high pressure/hightemperature conditions to form the composite material comprising aplurality of sintered granules distributed within a sintered continuousmatrix of material formed from the second mixture.
 10. The method asrecited in claim 9 wherein the sintered granules are polycrystallinediamond.
 11. The mcthod as recited in claim 9 wherein the sinteredcontinuous matrix is cemented tungsten carbide.
 12. The method asrecited in claim 9 wherein the sintered composite material comprises inthe range of from 10 to 90 percent by volume of the granules based onthe total volume of the composite.
 13. The method as recited in claim 9wherein the first and second polymer binders are selected from the groupof materials consisting of thermoplastics, thermosets, aqueous polymers,gelation polymers, and mixtures thereof.
 14. The method as recited inclaim 9 further comprising, after the step of forming a plurality ofgranules, coating the granules with a material selected from the groupconsisting of metals and cermets.
 15. A method for forming a compositematerial comprising the steps of: combining diamond powder and a firstpolymer binder to form a first mixture; forming the first mixture into aplurality of granules; combining one or mare powders selected from thegroup consisting of tungsten carbide, cemented tungsten carbide, cobalt,iron, nickel, and mixtures thereof, with a second polymer binder to forma second mixture; combining the plurality of granules with the secondmixture to form a third mixture in the form of a slurry and forming thethird mixture into a green-state art; and consolidating the thegreen-state part under high pressure/high temperature conditions to forma composite material having a microstructure comprising a plurality ofpolycrystalline diamond granules distributed within a substantiallycontinuous matrix formed from the second mixture, wherein the compositematerial comprises in the range of from 10 to 90 percent by volume ofthe polycrystalline diamond granules based on the total volume of thecomposite material.
 16. The method as recited in claim 1 wherein duringthe step of combining, the second mixture is placed into direct contactwith plurality of granules.
 17. The method as recited in claim 1 whereinprior to the step of combining, the granules are coated with a materialselected from the group consisting of metals and cermets.
 18. The methodas recited in claim 9 wherein during the step of combining the pluralityof granules, the second mixture is placed into direct contact withplurality of granules.
 19. The method as recited in claim 9 whereinprior to tho step of combining the plurality of granules, the granulesare coated with a material selected from the group consisting of metalsand cermets.